I have a 92 F150 4.9 I6 4wd and 5 speed manual. I have about reached the end of my troubleshooting skills and if i cant figure out what is wrong i'm going to junk the truck. no matter what gear i put the truck in it will not move under its own power. i have the transmission, transfer case and clutch out of the truck, the clutch plate looks fine the cover plate has a large amount of dirt and nastiness in it, the shafts of the transfer case and transmission will spin when in gear like they should. the rear and front differentials operate like normal, but the truck will not move. it starts like normal, runs and idles fine but will not move when in gear. anybody got an idea of what the problem could be? i have taken the powertrain out and put it back in about 5 times and don't wanna do it again. any help would be appreciated

 

Ok, lets clarify on the not moving. When the truck was together and running, if you put it in gear and popped the clutch, did it stall or did the engine spin and the truck go no where?

 

when it was put together and the clutch was let out the motor would spin just fine, but the truck wouldn't go anywhere

 

This might sound dumb but have you tried bleeding the hydraulic clutch system? Worth a try.

 

did it do it in all transfer case gears or just 2H?

 

Didnt try while the drivetrain was put together but the transfer case spins all shafts as it should when i turn it by hand in all gears

 

Any pics of the clutch "nastyness"? I once worked on an f150 3 on the tree, that had a bad column that jammed in third, and the owner destroyed the clutch driving it to the shop only having third, when we got it, it wouldn't go. I've also seen transfer case components break that might cause it to pull in one gear or another. Did you have any kind of noise, like a grinding perhaps from a gear that would partially engage?

 

The "cover plate" is the pressure plate. The springs can wear out, it will no longer grab the clutch disc as hard, clutch will slip, then eventually burn out. The pressure plate should be fairly clean. The dirt and nastyness you see on it is probably burnt clutch combined with brake fluid from the clutch slave.

You should go to your favorite autoparts store, and pick up a clutch kit with disc, alignment tool and pressure plate, and a new clutch slave cylinder.

 

Yeah with a burnt clutch it will let the motor spin to your hearts content but you won't go anywhere. Does your flywheel look like a mirror?

 

The flywheel looks fine, not mirrored, and to clarify the nastiness, its caked in mud and grass. I will try to change out the clutch as i have already changed out the slave cyl.(dont buy one from autozone btw, went through 3 of them that blew up while bleeding before i went to NAPA)

 

Also check the transfercase/transmission. Have someone grab the output shaft, while you try to turn the input shaft.

There is enough friction just from the oil that the out put shaft will turn without necessarily being in gear. If the shafts still turn without slipping, then the issue has to be the clutch.